Method for assembling fabric to an article of furniture

ABSTRACT

A method is provided for assembling a fabric material, such as woven cane, in a channel which surrounds an opening in an article of furniture, and which eliminates the usual manual edge trimming operation. The method includes the steps of cutting the fabric material into a component having a predetermined outline which conforms in an oversized relationship to the outline of the channel in the article of furniture, applying indicia to the component at at least two predetermined locations which are specifically located with respect to the outline of the associated channel of the article of furniture, placing the fabric component to overlie the opening in the article of furniture while utilizing the indicia to accurately orient the component with respect to the opening, and then forcing the peripheral edge of the component into the channel. By design, the entire extent of the peripheral edge of the component enters the channel, so that no portion of the edge extends out from the channel, and thus no manual trimming is required.

The present invention relates to a method for assembling a fabric material, such as woven cane, in a peripheral channel or groove which surrounds an opening in an article of furniture, and so as to cover the opening therein.

Cane has long been utilized in forming the seat or back of chairs. Traditionally, strands of the cane were hand woven directly across the opening of the seat or back, but more recently, it has become common to initially weave the strands of either natural cane, or a similar paper based material (referred to in the art as paper cane) into a desired pattern, and then to secure cut components of the pre-woven material across the opening in the furniture. More particularly, a peripheral channel or groove is initially routed or otherwise formed about the opening in the furniture, and the woven cane, which is typically supplied in large rolls, is then cut into oversized components which are positioned across the opening in the seat or back. The edge of the component is then forced into the channel by means of a die or suitable hand tool. In the case of natural cane, the component is preferably soaked in water just prior to being forced into the channel, to soften the material and facilitate its entry into the channel without breakage of the strands. Since the cane component is oversized, a peripheral outer edge portion extends from the routed channel after being forced therein, and this excess edge portion is manually severed, using a hand held knife. To lock the cane in the routed channel, glue is often applied over the cane in the channel, and a spline is usually forced over the cane in the glued channel to retain the edge of the cane therein.

The required manual cutting of the excess edge portion of the cane not only increases the cost of the assembly operation by reason of the labor and time required, but also, this operation often tends to distort the cane pattern along the severed edges to thereby result in a non-uniform appearance. Also, the knife often slips onto the finished portion of the furniture, causing a visible line or crease. Finally, as will be apparent, the severing operation is dangerous to the laborer.

As a further disadvantage of the above present procedure, the woven cane components are not always assembled with the cane pattern consistently oriented from chair to chair, to thereby produce non-uniformity in appearance among a given set of chairs.

It is accordingly an object of the present invention to provide a method for assembling a fabric material to cover an opening in an article of furniture, and which effectively overcomes the above noted deficiencies of the present procedure.

It is a more particular object of the present invention to provide a method for assembling a woven cane material to cover an opening in an article of furniture, which minimizes manual operations, and in particular, eliminates the edge trimming operation.

It is still another object of the present invention to provide a method for assembling a woven cane material to an article of furniture, and wherein the pattern of the woven cane is consistently aligned and oriented on each article of furniture, so as to provide uniformity from article to article.

These and other objects and advantages of the present invention are achieved in the embodiment illustrated herein by the provision of a method which includes the steps of cutting the fabric material into components which have a peripheral edge which accurately conforms in a predetermined oversized relationship to the peripheral outline of the channel in the article of furniture, and so that the component is adapted to overlie the opening in the article of furniture with the entire extent of the peripheral edge of the component being disposed within the channel. Next, indicia are applied at at least two widely spaced positions on the component, with the positions being respectively disposed at predetermined locations with respect to the peripheral outline of the associated channel. Thereafter, the component is aligned so as to overlie the opening in the article of furniture, and the indicia are located at the predetermined locations with respect to the peripheral outline of the channel in the article of furniture. Finally, the peripheral edge of the component is forced into the channel. Since by design the entire peripheral edge of the component is thereby disposed within the channel, no portion thereof extends from the channel after being forced therein, and as a result, there is no need for trimming any excess edge portion.

In the preferred embodiment, the fabric material is initially cut into rectangular segments, which are consistently oriented in a predetermined manner with respect to the weave pattern. During the cutting step, the edge of the resulting segment is oriented in a predetermined manner with respect to the predetermined locations, so that the pattern of the woven material is consistently oriented with respect to its edge, and with the predetermined locations, from component to component.

Some of the objects and advantages of the invention having been stated, others will appear as the description proceeds, when taken in connection with the accompanying drawings, in which

FIG. 1 is a flow chart indicating the steps of the method of the present invention;

FIG. 2 is a schematic perspective view of a cutting apparatus for cutting a woven fabric material on the bias to form oversized rectangular components;

FIG. 3 is a schematic perspective view of a die cutting apparatus for trimming the rectangular components to a precise predetermined outline;

FIG. 4 is a sectional elevation view of the die cutting apparatus in the closed or cutting position;

FIG. 5 is a perspective view of a plurality of stacked components after having been trimmed on the cutting apparatus;

FIG. 6 is a fragmentary plan view illustrating the indicium applied to the fabric;

FIG. 7 is a schematic perspective view of an apparatus for assembling the fabric components to an article of furniture;

FIG. 8 is a sectional elevation view of the assembly apparatus in its closed position;

FIG. 9 is a perspective view of the assembly table of the assembly apparatus, and with the article of furniture positioned thereon; and

FIG. 10 is a fragmentary sectional view of the article of furniture illustrating the manner in which the fabric component is secured in the channel.

Referring more specifically to the drawings, the present invention is illustrated and described herein in association with the wooden chair back 12 (FIG. 7) prior to its being fabricated into a completed dining room chair or the like. The chair back includes an opening 14 which is surrounded by a channel 15 routed in one face thereof, and the present invention relates to the assembly of an openwork, woven cane material to cover the opening 14 in the chair back. It will be understood however, that the novel features of the present invention are not limited to the assembly of woven cane in a chair back, and are equally applicable in any number of similar assembly operations where a fabric is assembled in a continuous channel formed in an article of furniture.

The fabric material, which as illustrated comprises an openwork woven material of either natural or "paper" cane, is usually supplied in a large roll as indicated at 16 in FIG. 2. In accordance with the illustrated embodiment of the present invention, the fabric material is unwound from the roll 16 onto a cutting table 18, where it is cut on a 45 degree bias to initially form intermediate fabric products 20. The intermediate products are thereafter cut transversely along the indicated dashed lines 21 to form oversized rectangular fabric segments 22 (FIG. 3). By this arrangement, the side edges of the resulting rectangular segments 22 are oriented in a consistent and predetermined manner with respect to the weave pattern.

The rectangular segments 22 are individually delivered to a die cutting apparatus as schematically illustrated at 24 in FIGS. 3 and 4, and which comprises a rectangular bed 26 and a vertically reciprocable cutting plate 27. The cutting plate includes a continuous flange or cutting blade 28, which by design accurately conforms in a predetermined oversized relationship to the peripheral outline of the channel 15 formed about the opening in the chair back 12. More particularly, the blade 28 is configured so as to be adapted to cut the segments 22 into components 30 having a peripheral edge which also accurately conforms in the predetermined oversized relationship to the peripheral outline of the channel 15, and so that the component is adapted to overlie the opening in the chair back with the entire extent of the peripheral edge thereof being disposed within the channel, and as illustrated in FIG. 10.

The bed 26 includes two widely spaced pins 32, 33 fixed thereon, and the segments 22 are individually placed on the bed such that the pins 32, 33 penetrate respective interstices of the fabric, note FIG. 6. Also, one side edge of the rectangular segment 22 is aligned with the edge of the bed, or with a suitable marking (not shown) on the bed, to thereby insure that the weave pattern is consistently oriented on the bed from component to component. The interstices penetrated by the pins 32, 33 define predetermined locations on the segment 22, and thus the resulting component 30, with respect to the peripheral outline of the associated channel, for the purposes described below. Also, an indicium in the form of a releasble sticker 35 or other suitable mark is applied to the segment 22 while it is positioned on the bed 26 so as to indicate each of the interstices through which the pins 32, 33 have penetrated. As illustrated, the sticker 35 includes a printed arrow 36 which points to the appropriate interstices.

To effect cutting, the cutting plate 27 is lowered by a suitable mechanism (not shown) to the position illustrated in FIG. 4. The plate 27 is then raised and the resulting component 30 is removed from the bed and placed on a stack of similar components as shown in FIG. 5. As will become apparent, these initial steps of the process may be conducted at one location, such as the plant at which the fabric is woven, and the remaining steps as described below may be carried out at a remote furniture plant to which the components 30 are shipped.

The assembly of the fabric component 30 to the chair back 12 utilizes an apparatus as schematically illustrated at 37 in FIGS. 7-9, and which includes a table 38 having guide means in the form of three posts 40 for accurately positioning the chair back 12 thereon at a predetermined location. Also, the table 38 mounts a pair of upstanding pegs 41, 42 which by design are respectively positioned at each of the above defined predetermined locations with respect to the channel 15 of the thusly placed chair back 12. The apparatus 37 further includes an upper vertically reciprocable die plate 44, which has a downwardly directed continuous flange 45 which is shaped to match the outline of the channel 15 in the chair back 12.

With the chair back 12 positioned on the table 38, a cut fabric component 30 is positioned so as to overlie the opening 14 therein, and the component 30 is aligned so that the pegs 41, 42 penetrate the interstices indicated by the stickers 35. Stated in other words, the pegs 41, 42 penetrate the same interstices which were previously penetrated by the pins 32, 33 at the die cutting apparatus. As will thus be apparent, the component 30 is thereby aligned with respect to the channel 15 in the chair back 12, so that the peripheral edge of the component accurately conforms in the desired oversized relationship to the peripheral outline of the channel 15. Further, upon the plate 44 being lowered to the position of FIG. 8, the entire edge of the component 30 is concurrently forced into the channel, and the entire extent of the peripheral edge of the component will be wholly disposed within the channel, without any portion of the edge extending back out and beyond the channel. Thus any need for a subsequent trimming operation is avoided. During this forcing process, the pegs 41, 42 serve the further function of preventing the component 30 from laterally shifting with respect to the channel.

In the case of natural cane, the component 30 is preferably soaked in water to soften the cane just prior to the peripheral edge being forced into the channel, to thereby avoid possible breakage of the cane strips at the edge. The wetting also causes the cane to shrink slightly while drying, to provide added tightness across the opening.

To complete the assembly operation, a spline 46 (FIG. 10) is placed within the channel along the full extent thereof and upon the peripheral edge of the component. Preferably, glue is also applied within the channel, to securely retain the edge of the component and the spline therein. A finish may be thereafter applied to the cane in a conventional manner after the chair is fully assembled.

In the drawings and specification, there has been set forth a preferred embodiment of the invention, and although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation. 

That which is claimed is:
 1. A method for assembling a fabric material, such as woven cane, in a continuous channel in an article of furniture, and so as to cover the area encompassed by the channel, and characterized by the absence of a manual trimming operation, and comprising the steps ofcutting the fabric material into a component having a peripheral edge which accurately conforms in a predetermined oversized relationship to the peripheral outline of the channel in the article of furniture and so that the component is adapted to overlie the area encompassed by the channel with the entire extent of the peripheral edge of the component being disposed within the channel, applying indicium at at least two widely spaced positions on the component, with said positions being respectively disposed to indicate predetermined locations with respect to the peripheral outline of the associated channel in the article of furniture, placing the component with the indicia applied thereto so as to overlie the area encompassed by the channel in the article of furniture, while orienting the indicia on the component at said predetermined locations with respect to the peripheral outline of the channel, and then forcing the peripheral edge of the component into the channel, and whereby the entire extent of the peripheral edge of the component is disposed within the channel.
 2. The method as defined in claim 1 wherein the step of cutting the fabric material includes aligning the pattern of the fabric in a predetermined manner with respect to the resulting peripheral edge of the cut component, and so that the pattern is consistently oriented with respect to its edge from component to component.
 3. The method as defined in either of claims 1 or 2 wherein the step of forcing the peripheral edge of the component into the channel includes moving the entire peripheral edge concurrently into the channel.
 4. The method as defined in claim 1 comprising the further subsequent step of placing a spline within the channel and upon the peripheral edge of said component, to retain the edge thereof in the channel.
 5. The method as defined in claim 4 comprising the further step of applying glue within the channel to further retain the edge of the component and the spline therein.
 6. The method as defined in claim 1 wherein the step of cutting the fabric material comprises placing the fabric material on the bed of a die cutting apparatus, with the bed having means fixed thereon for indicating each of said predetermined locations on the cut component.
 7. The method as defined in claim 6 wherein the step of applying indicium is carried out while the fabric material is on the bed of the die cutting apparatus, and while referencing said indicating means thereon.
 8. The method as defined in claim 7 wherein the step of placing the component to overlie the area encompassed by the channel in the article of furniture includes placing the article of furniture on an assembly table having guide means for accurately locating the article of furniture thereon and locating means for indicating each of said predetermined locations with respect to the channel of the thusly placed article of furniture, and the orienting of the indicia on the component at said predetermined locations includes aligning said indicia with respect to said locating means of said table.
 9. A method for assembling an openwork, woven fabric material, such as woven cane, in a channel which surrounds an opening in an article of furniture, and so as to cover the opening therein, and characterized by the absence of a manual trimming operation, and comprising the steps ofcutting the fabric material into a rectangular segment with the side edges thereof being oriented in a predetermined manner with respect to the weave pattern, placing the fabric segment on the bed of a die cutting apparatus having at least two widely spaced pins fixed thereon and while orienting the edge of the segment in a predetermined manner with respect to said pins, and such that the pins penetrate respective interstices of the oriented fabric, cutting the fabric segment while it is placed upon said bed into a component having a peripheral edge which accurately conforms in a predetermined oversized relationship to the peripheral outline of the channel in the article of furniture and so that the component is adapted to overlie the opening in the article of furniture with the entire extent of the peripheral edge of the component being disposed within the channel, and such that the interstices penetrated by the pins define predetermined locations on the component with respect to the peripheral outline of the associated channel, applying indicia on the component so as to indicate each of the interstices through which said pins have penetrated, placing the article of furniture upon an assembly table having guide means for accurately positioning the article of furniture thereon and upstanding pegs which are respectively positioned at each of said predetermined locations with respect to the channel of the thusly placed article of furniture, placing the cut fabric component with the indicia applied thereto so as to overlie the opening in the thusly placed article of furniture, and including orienting the component so that the pegs penetrate the interstices indicated by the indicia, and then forcing the peripheral edge of the component into the channel, and whereby the entire extent of the peripheral edge of the component is disposed within the channel.
 10. The method as defined in claim 9 wherein the entire peripheral edge of the component is concurrently forced into the channel, and comprising the further subsequent step of placing a spline within the channel along the full extent thereof and so as to retain the peripheral edge of the component in the channel. 